Air conditioner units and methods for determining indoor room temperatures

ABSTRACT

Air conditioner units and methods for determining indoor room temperatures are provided. A method includes calculating a difference between a first temperature received from a first temperature sensor and a second temperature received from a second temperature sensor. The first and second temperature sensors are disposed within an indoor portion of an air conditioner unit, the first temperature sensor disposed proximate an indoor heat exchanger of the air conditioner unit, the second temperature sensor spaced from the indoor heat exchanger relative to the first temperature sensor. The method further includes modifying the second temperature based on the difference to obtain a corrected temperature, and outputting the corrected temperature.

FIELD OF THE INVENTION

The present disclosure relates generally to air conditioner units andmethods for operating air conditioner units, and more particularly tomethods and apparatus for air conditioner units to accurately determineindoor air temperatures.

BACKGROUND OF THE INVENTION

Air conditioner units are conventionally utilized to adjust thetemperature within structures such as dwellings and office buildings. Inparticular, one-unit type room air conditioner units may be utilized toadjust the temperature in, for example, a single room or group of roomsof a structure. A typical such air conditioner unit includes an indoorportion and an outdoor portion. The indoor portion is generally locatedindoors, and the outdoor portion is generally located outdoors.Accordingly, the air conditioner unit generally extends through a wall,window, etc. of the structure.

In the outdoor portion of a conventional air conditioner unit, acompressor that operates a refrigerating cycle is provided. At the backof the outdoor portion, an outdoor heat exchanger connected to thecompressor is disposed, and facing the outdoor heat exchanger, anoutdoor fan for cooling the outdoor heat exchanger is provided. At thefront of the indoor portion of a conventional air conditioner unit, anair inlet is provided, and above the air inlet, an air outlet isprovided. A blower fan and a heating unit may additionally be providedin the indoor portion. Between the blower fan and heating unit and theair inlet, an indoor heat exchanger connected to the compressor isprovided.

When cooling operation starts, the compressor is driven to operate therefrigerating cycle, with the indoor heat exchanger serving as acold-side evaporator of the refrigerating cycle, and the outdoor heatexchanger as a hot-side condenser. The outdoor heat exchanger is cooledby the outdoor fan to dissipate heat. As the blower fan is driven, theair inside the room flows through the air inlet into the air passage,and the air has its temperature lowered by heat exchange with the indoorheat exchanger, and is then blown into the room through the air outlet.In this way, the room is cooled.

When heating operation starts, the compressor may be driven to operate aheat pump cycle, with the indoor heat exchanger serving as a hot-sidecondenser and the outdoor heat exchanger as a cold-side evaporator. Theheating unit may additionally be operated to raise the temperature ofair in the air passage. As the blower fan is driven, the air inside theroom flows through the air inlet into the air passage, and the air hasits temperature raised by heat exchange with the indoor heat exchanger,and is then blown into the room through the air outlet. In this way, theroom is heated.

Further, conventional air conditioner units include a bulkhead which ispositioned between the indoor portion and outdoor portion, and thusgenerally separates the components within the indoor portion from thecomponents in the outdoor portion. Various components may additionallybe connected to the bulkhead, such as the blower fan and heating unit.

A typical air conditioner unit includes one or more temperature sensorsfor sensing various indoor and outdoor temperatures. For example, anindoor temperature sensor may be provided for measuring the indoortemperature. Further, in some embodiments, an additional sensor may beprovided in the indoor portion for measuring the temperature of thecoils of the indoor heat exchanger.

In some cases, issues may arise with the accuracy of the indoor ambienttemperature readings of the indoor temperature sensor. For example, thesensor may become inaccurate when the blower fan is shut off andsignificant airflow through the indoor heat exchanger is ceased.Specifically, the temperature of the indoor heat exchanger and coilsthereof may bias the readings of the indoor temperature sensor. Suchbiasing may be caused by the outdoor temperature and attempts by thesealed thermodynamic assembly to obtain pressure equalization. Forexample, when the air conditioner unit is operating in a refrigeratingcycle, the indoor temperature sensor may initially sense a temperaturelower than the indoor ambient temperature, due to the temperature of therefrigerant in the indoor heat exchanger. The indoor temperature sensormay then gradually transition to sensing a temperature higher than theindoor ambient temperature, due to the outdoor (presumably hotter) airheating the refrigerant. When the air conditioner unit is operating in aheat pump cycle, the indoor temperature sensor may initially sense atemperature higher than the indoor ambient temperature, due to thetemperature of the refrigerant in the indoor heat exchanger. The indoortemperature sensor may then gradually transition to sensing atemperature lower than the indoor ambient temperature, due to theoutdoor (presumably colder) air cooling the refrigerant. Additionally,biasing can occur due to heat retention (or heat transmission to theindoor heat exchanger) by the coils of the heating unit when the blowerfan is shut off.

Accordingly, improved air conditioner units and methods for determiningindoor room temperatures are desired. In particular, methods andapparatus which facilitate accurate indoor temperature readings would beadvantageous.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in thefollowing description, or may be obvious from the description, or may belearned through practice of the invention.

In accordance with one embodiment, an air conditioner unit is provided.The air conditioner unit includes an outdoor heat exchanger disposed inan outdoor portion, an indoor heat exchanger disposed in an indoorportion, and a bulkhead disposed between the outdoor heat exchanger andthe indoor heat exchanger along a transverse direction, the bulkheaddefining the indoor portion and the outdoor portion. The air conditionerunit further includes a first temperature sensor disposed within theindoor portion and proximate the indoor heat exchanger, and a secondtemperature sensor disposed within the indoor portion and spaced fromthe indoor heat exchanger relative to the first temperature sensor. Theair conditioner unit further includes a controller in communication withthe first temperature sensor and the second temperature sensor. Thecontroller is configured for calculating a difference between a firsttemperature received from the first temperature sensor and a secondtemperature received from the second temperature sensor, modifying thesecond temperature based on the difference to obtain a correctedtemperature, and outputting the corrected temperature.

In accordance with another embodiment, a method for determining anindoor room temperature is provided. The method includes calculating adifference between a first temperature received from a first temperaturesensor and a second temperature received from a second temperaturesensor. The first and second temperature sensors are disposed within anindoor portion of an air conditioner unit, the first temperature sensordisposed proximate an indoor heat exchanger of the air conditioner unit,the second temperature sensor spaced from the indoor heat exchangerrelative to the first temperature sensor. The method further includesmodifying the second temperature based on the difference to obtain acorrected temperature, and outputting the corrected temperature.

These and other features, aspects and advantages of the presentinvention will become better understood with reference to the followingdescription and appended claims. The accompanying drawings, which areincorporated in and constitute a part of this specification, illustrateembodiments of the invention and, together with the description, serveto explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof, directed to one of ordinary skill in the art, is setforth in the specification, which makes reference to the appendedfigures, in which:

FIG. 1 provides a perspective view of an air conditioner unit, with aroom front exploded from a remainder of the air conditioner unit forillustrative purposes, in accordance with one embodiment of the presentdisclosure;

FIG. 2 is a perspective view of components of an indoor portion of anair conditioner unit in accordance with one embodiment of the presentdisclosure;

FIG. 3 is a rear perspective view of a bulkhead assembly in accordancewith one embodiment of the present disclosure;

FIG. 4 is another perspective view of components of an indoor portion ofan air conditioner unit in accordance with one embodiment of the presentdisclosure;

FIG. 5 is a cross-sectional view of components of an indoor portion ofan air conditioner unit in accordance with one embodiment of the presentdisclosure; and

FIG. 6 is a flow chart illustrating a method in accordance with oneembodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to embodiments of the invention,one or more examples of which are illustrated in the drawings. Eachexample is provided by way of explanation of the invention, notlimitation of the invention. In fact, it will be apparent to thoseskilled in the art that various modifications and variations can be madein the present invention without departing from the scope or spirit ofthe invention. For instance, features illustrated or described as partof one embodiment can be used with another embodiment to yield a stillfurther embodiment. Thus, it is intended that the present inventioncovers such modifications and variations as come within the scope of theappended claims and their equivalents.

Referring now to FIG. 1, an air conditioner unit 10 is provided. The airconditioner unit 10 is a one-unit type air conditioner, alsoconventionally referred to as a room air conditioner. The unit 10includes an indoor portion 12 and an outdoor portion 14, and generallydefines a vertical direction V, a lateral direction L, and a transversedirection T. Each direction V, L, T is perpendicular to each other, suchthat an orthogonal coordinate system is generally defined.

A housing 20 of the unit 10 may contain various other components of theunit 10. Housing 20 may include, for example, a rear grill 22 and a roomfront 24 which may be spaced apart along the transverse direction by awall sleeve 26. The rear grill 22 may be part of the outdoor portion 14,which the room front 24 is part of the indoor portion 12. Components ofthe outdoor portion 14, such as an outdoor heat exchanger 30, outdoorfan (not shown), and compressor 32 may be housed within the wall sleeve26. A casing 34 may additionally enclose the outdoor fan, as shown.

Referring now also to FIG. 2, indoor portion 12 may include, forexample, an indoor heat exchanger 40, a blower fan 42, and a heatingunit 44. These components may, for example, be housed behind the roomfront 24. Additionally, a bulkhead 46 may generally support and/or housevarious other components or portions thereof of the indoor portion 12,such as the blower fan 42 and the heating unit 44. Bulkhead 46 maygenerally separate and define the indoor portion 12 and outdoor portion14.

Outdoor and indoor heat exchangers 30, 40 may be components of athermodynamic assembly which may alternately be operated as arefrigeration assembly (and thus perform a refrigeration cycle) or aheat pump (and thus perform a heat pump cycle). The assembly may, forexample, further include compressor 32 and an expansion valve, both ofwhich may be in fluid communication with the heat exchangers 30, 40 toflow refrigerant therethrough as is generally understood. When theassembly is operating in a cooling mode and thus performs arefrigeration cycle, the indoor heat exchanger 40 acts as an evaporatorand the outdoor heat exchanger 30 acts as a condenser. When the assemblyis operating in a heating mode and thus performs a heat pump cycle, theindoor heat exchanger 40 acts as a condenser and the outdoor heatexchanger 30 acts as an evaporator. The outdoor and indoor heatexchangers 30, 40 may each include coils 31, 41, as illustrated, throughwhich a refrigerant may flow for heat exchange purposes, as is generallyunderstood.

Bulkhead 46 may include various peripheral surfaces that define aninterior 50 thereof. For example, and additionally referring to FIG. 3,bulkhead 46 may include a first sidewall 52 and a second sidewall 54which are spaced apart from each other along the lateral direction L. Arear wall 56 may extend laterally between the first sidewall 52 andsecond sidewall 54. The rear wall 56 may, for example, include an upperportion 60 and a lower portion 62. Upper portion 60 may for example havea generally curvilinear cross-sectional shape, and may accommodate aportion of the blower fan 42 when blower fan 42 is housed within theinterior 50. Lower portion 62 may have a generally linearcross-sectional shape, and may be positioned below upper portion 60along the vertical direction V. Rear wall 56 may further include anindoor facing surface 64 and an opposing outdoor facing surface. Theindoor facing surface 64 may face the interior 50 and indoor portion 12,and the outdoor facing surface 66 may face the outdoor portion 14.

Bulkhead 46 may additionally extend between a top end 61 and a bottomend 63 along vertical axis V. Upper portion 60 may, for example, includetop end 61, while lower portion 62 may, for example, include bottom end63.

Bulkhead 46 may additionally include, for example, an air diverter 68,which may extend between the sidewalls 52, 54 along the lateraldirection L and which may flow air therethrough.

In exemplary embodiments, blower fan 42 may be a tangential fan.Alternatively, however, any suitable fan type may be utilized. Blowerfan 42 may include a blade assembly 70 and a motor 72. The bladeassembly 70, which may include one or more blades disposed within a fanhousing 74, may be disposed at least partially within the interior 50 ofthe bulkhead 46, such as within the upper portion 60. As shown, bladeassembly 70 may for example extend along the lateral direction L betweenthe first sidewall 52 and the second sidewall 54. The motor 72 may beconnected to the blade assembly 70, such as through the housing 74 tothe blades via a shaft. Operation of the motor 72 may rotate the blades,thus generally operating the blower fan 42. Further, in exemplaryembodiments, motor 72 may be disposed exterior to the bulkhead 46.Accordingly, the shaft may for example extend through one of thesidewalls 52, 54 to connect the motor 72 and blade assembly 70.

Heating unit 44 in exemplary embodiments includes one or more heaterbanks 80. Each heater bank 80 may be operated as desired to produceheat. In some embodiments as shown, three heater banks 80 may beutilized. Alternatively, however, any suitable number of heater banks 80may be utilized. Each heater bank 80 may further include at least oneheater coil or coil pass 82, such as in exemplary embodiments two heatercoils or coil passes 82. Alternatively, other suitable heating elementsmay be utilized.

The operation of air conditioner unit 10 including compressor 32 (andthus the thermodynamic assembly generally) blower fan 42, heating unit44, and other suitable components may be controlled by a processingdevice such as a controller 85. Controller 85 may be in communication(via for example a suitable wired or wireless connection) to suchcomponents of the air conditioner unit 10. By way of example, thecontroller 85 may include a memory and one or more processing devicessuch as microprocessors, CPUs or the like, such as general or specialpurpose microprocessors operable to execute programming instructions ormicro-control code associated with operation of unit 10. The memory mayrepresent random access memory such as DRAM, or read only memory such asROM or FLASH. In one embodiment, the processor executes programminginstructions stored in memory. The memory may be a separate componentfrom the processor or may be included onboard within the processor.

Unit 10 may additionally include a control panel 87 and one or more userinputs 89, which may be included in control panel 87. The user inputs 89may be in communication with the controller 85. A user of the unit 10may interact with the user inputs 89 to operate the unit 10, and usercommands may be transmitted between the user inputs 89 and controller 85to facilitate operation of the unit 10 based on such user commands. Adisplay 88 may additionally be provided in the control panel 87, and maybe in communication with the controller 85. Display 88 may, for examplebe a touchscreen or other text-readable display screen, or alternativelymay simply be a light that can be activated and deactivated as requiredto provide an indication of, for example, an event or setting for theunit.

Referring now to FIGS. 1, 4 and 5, a first temperature sensor 92 and asecond temperature sensor 94 may be disposed within the indoor portion12. Each temperature sensor may be configured to sense the temperatureof its surroundings. The temperature sensors 92, 94 may be incommunication with the controller 85, and may transmit temperaturessensed thereby to the controller 85.

First temperature sensor 92 may be disposed proximate the indoor heatexchanger 40 (such as relative to the second temperature sensor 94). Forexample, in some embodiments, first temperature sensor 92 may be incontact with the indoor heat exchanger 40, such as with a coil 41thereof. Second temperature sensor 94 may be spaced from the indoor heatexchanger 40, such as in the transverse direction T. For example, thesecond temperature sensor 94 may be in contact with the room front 24,as illustrated in FIG. 1.

Referring now also to FIG. 6, the present disclosure may further bedirected to methods 100 for determining indoor air temperatures. Suchmethods may advantageously utilize temperatures sensed by and obtainedfrom the first and second temperature sensors 92, 94. In exemplaryembodiments, controller 85 may be operable to perform various steps of amethod in accordance with the present disclosure.

For example, a method 100 may include the step 110 determining whetherthe indoor heat exchanger 40 is in a heating mode or a cooling mode. Forexample, controller 85 may, based on instructions transmitted thereby tothe compressor 32 and thermodynamic assembly generally, sense whethercurrent operation is in a heating mode or a cooling mode. The currentmode of operation may, for example, determine the manner in whichvarious subsequent steps are carried out. Notably, the thermodynamicassembly being generally in a particular mode does not require that theassembly generally is active. Rather, being in a particular mode mayrequire only that the thermodynamic assembly is configured foractivation in that particular mode and/or was active in that particularmode immediately prior to such determination by controller 85.

Method 100 may further include, for example, the step 120 of calculatinga difference 122 between a first temperature 102 received from the firsttemperature sensor 92 and a second temperature 104 received from thesecond temperature sensor 94. The received temperatures 102, 104 may betemperatures sensed by the sensors 92, 94 at the same time. Such stepmay occur, for example, when the blower fan 42 is not operating, such asimmediately after heating or cooling operations (i.e. immediately afteractive operation of the thermodynamic assembly). In some embodiments,such step may occur only when the blower fan 42 is not operating. Inthese embodiments, for example, the second temperature 104 may be theoutput temperature when the blower fan 42 is operating.

For example, when the indoor heat exchanger 40 is in the cooling mode,step 120 may include subtracting the second temperature 104 from thefirst temperature 102. When the indoor heat exchanger 40 is in theheating mode, step 120 may include subtracting the first temperature 102from the second temperature 104.

Notably, in some embodiments, the calculating step 120 may only occur inthe case of a particular temperature differential. For example, when theindoor heat exchanger 40 is in the cooling mode, the calculating step120 in some embodiments may only occur when the first temperature 102 isgreater than the second temperature 104. When the indoor heat exchanger40 is in the heating mode, the calculating step 120 in some embodimentsmay only occur when the second temperature 104 is greater than the firsttemperature 102.

Method 100 may further include, for example, the step 130 of applying apredetermined correction factor 132 to the difference 122 to obtain acorrected difference 132. The predetermined correction factor 132 may,for example, be an empirically determined amount, such as a percentage,and may for example, be empirically determined based on varioustemperature, temperature ranges and/or indoor-outdoor temperaturedifferences. Step 130 may include, for example, multiplying thedifference 122 by the predetermined correction factor 132. Typically,such application may result in a corrected difference 132 that is lessthan the difference 122.

Method 100 may further include, for example, the step 140 of modifyingthe second temperature 104 based on the difference 122 to obtain acorrected temperature 142. In embodiments wherein the step 130 isinclude in the method, the second temperature 104 may be modified basedon the corrected difference 132 to obtain the corrected temperature 142.For example, when the indoor heat exchanger 40 is in the cooling mode,the modifying step 140 may include decreasing the second temperature 104based on the difference 122 (or corrected difference 132) to obtain thecorrected temperature 142. In other words, the difference 122 (orcorrected difference 132) may be subtracted from the second temperature104 to obtain the corrected temperature 142. When the indoor heatexchanger 40 is in the heating mode, the modifying step 140 may includeincreasing the second temperature 104 based on the difference 122 (orcorrected difference 132) to obtain the corrected temperature 142. Inother words, the difference 122 (or corrected difference 132) may beadded to the second temperature 104 to obtain the corrected temperature142.

Method 100 may further include, for example, the step 150 of outputtingthe corrected temperature 142. The corrected temperature 142 may, forexample, be output to the display 88. Further, the corrected temperature142 may be output for use in other functions of the unit 10, such as indetermining when to activate the thermodynamic assembly for furtherheating or cooling.

Accordingly, units 10 and methods 100 in accordance with the presentdisclosure advantageously provide improved accuracy of indoortemperature readings. Such improvement is advantageously provided byoffsetting sensed indoor temperatures by the second temperature sensor94 using sensed temperatures by the first temperature sensor 92 insituations wherein biasing of the sensed indoor temperature may occur.Improved resulting temperature readings and resulting operation of theunit 10 may result.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they include structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal languages of the claims.

What is claimed is:
 1. An air conditioner unit, comprising: an outdoorheat exchanger disposed in an outdoor portion; an indoor heat exchangerdisposed in an indoor portion; a bulkhead disposed between the outdoorheat exchanger and the indoor heat exchanger along a transversedirection, the bulkhead defining the indoor portion and the outdoorportion, a first temperature sensor disposed within the indoor portionand proximate the indoor heat exchanger; a second temperature sensordisposed within the indoor portion and spaced from the indoor heatexchanger relative to the first temperature sensor; and a controller incommunication with the first temperature sensor and the secondtemperature sensor, the controller configured for: calculating adifference between a first temperature received from the firsttemperature sensor and a second temperature received from the secondtemperature sensor; modifying the second temperature based on thedifference to obtain a corrected temperature; and outputting thecorrected temperature.
 2. The air conditioner unit of claim 1, whereinthe controller is further configured for applying a predeterminedcorrection factor to the difference to obtain a corrected difference,and wherein the second temperature is modified based on the correcteddifference to obtain the corrected temperature.
 3. The air conditionerunit of claim 1, wherein the controller is further configured fordetermining whether the indoor heat exchanger is in a heating mode or acooling mode.
 4. The air conditioner unit of claim 3, wherein thecalculating step comprises subtracting the second temperature from thefirst temperature when the indoor heat exchanger is in the cooling mode.5. The air conditioner unit of claim 3, wherein the modifying stepcomprises decreasing the second temperature based on the difference whenthe indoor heat exchanger is in the cooling mode.
 6. The air conditionerunit of claim 3, wherein the calculating step occurs only when the firsttemperature is greater than the second temperature when the indoor heatexchanger is in the cooling mode.
 7. The air conditioner unit of claim3, wherein the calculating step comprises subtracting the firsttemperature from the second temperature when the indoor heat exchangeris in the heating mode.
 8. The air conditioner unit of claim 3, whereinthe modifying step comprises increasing the second temperature based onthe difference when the indoor heat exchanger is in the heating mode. 9.The air conditioner unit of claim 3, wherein the calculating step occursonly when the second temperature is greater than the first temperaturewhen the indoor heat exchanger is in the heating mode.
 10. The airconditioner unit of claim 1, wherein the first temperature sensor is incontact with the indoor heat exchanger.
 11. The air conditioner unit ofclaim 1, wherein the first temperature sensor is in contact with a coilof the indoor heat exchanger.
 12. The air conditioner unit of claim 1,wherein the second temperature sensor is spaced from the indoor heatexchanger along the transverse direction.
 13. The air conditioner unitof claim 1, further comprising a blower fan and a heating unit eachdisposed at least partially within an interior of the bulkhead.
 14. Amethod for determining an indoor room temperature, the methodcomprising: calculating a difference between a first temperaturereceived from a first temperature sensor and a second temperaturereceived from a second temperature sensor, the first and secondtemperature sensors disposed within an indoor portion of an airconditioner unit, the first temperature sensor disposed proximate anindoor heat exchanger of the air conditioner unit, the secondtemperature sensor spaced from the indoor heat exchanger relative to thefirst temperature sensor; modifying the second temperature based on thedifference to obtain a corrected temperature; and outputting thecorrected temperature.
 15. The method of claim 14, further comprisingapplying a predetermined correction factor to the difference to obtain acorrected difference, and wherein the second temperature is modifiedbased on the corrected difference to obtain the corrected temperature.16. The method of claim 14, further comprising determining whether theindoor heat exchanger is in a heating mode or a cooling mode.
 17. Themethod of claim 16, wherein the calculating step comprises subtractingthe second temperature from the first temperature when the indoor heatexchanger is in the cooling mode.
 18. The method of claim 16, whereinthe calculating step occurs only when the first temperature is greaterthan the second temperature when the indoor heat exchanger is in thecooling mode.
 19. The method of claim 16, wherein the calculating stepcomprises subtracting the first temperature from the second temperaturewhen the indoor heat exchanger is in the heating mode.
 20. The method ofclaim 16, wherein the calculating step occurs only when the secondtemperature is greater than the first temperature when the indoor heatexchanger is in the heating mode.